Applied Mathematical Modelling 75 (2019) 37–51

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Applied Mathematical Modelling

journal homepage: www.elsevier.com/locate/apm

A general mathematical model for two-parameter generating

machining of involute cylindrical gears
Kang Jia a,b, Junkang Guo a,b, Shuai Zheng c, Jun Hong a,b,∗
a
Key Laboratory of Education Ministry for Modern Design & Rotor-Bearing System, Xi’an Jiaotong University, Xi’an 710049, P.R. China
b
School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, P.R. China
c
School of Software Engineering, Xi’an Jiaotong University, Xi’an 710049, P.R. China

a r t i c l e i n f o a b s t r a c t

Article history: Instead of the common analytical model for involute gears machining, a general mathe-
Received 8 June 2018 matical model for two-parameter generating machining is developed in this study with
Revised 8 May 2019
adopting discrete enveloping to increase its robustness and generality for machined profile
Accepted 15 May 2019
calculation and instant contact analysis. The geometric parameters and motion relation-
Available online 20 May 2019
ships are integrated according to the cross-axis gear meshing at first, and the envelop-
Keywords: ing theory for two-parameter generating process is analyzed briefly with involving middle
Generating machining gear rack. By transforming the multiple cutting edges relative to the gear blank according
Discrete enveloping to the generating motions, a numerical algorithm is proposed to distinguish the external
Instant contact line enveloping profile on the shaft section, then the derivation of instant contact points via
Two-parameter generating the implied time sequences of profile points is introduced. Finally, the coordinate trans-
Cylindrical gear formations for the spatial trajectory of instant contact points identifying and the engaged
General profiles cutting edge segments distinguishing are investigated. At last, a non- involute profile skiv-
ing is performed to verify the generality and the robustness of proposed method, and sev-
eral typically generating machining operations for cylindrical involute gear are simulated
numerically to proof the accuracy of the proposed model by finding the deviations from
the standard involute curves and the geometries of the instant contact points.
© 2019 Elsevier Inc. All rights reserved.

1. Introduction

Generating machining is a significant methodology for cylindrical involute gears manufacture. In practical, such as gear
hobbing, gear skiving, gear shaving, and generating grinding have been applied widely with respect to the high efficiency
and accuracy [1]. In general, the cutter and gear blank are installed as a pair of cross-axis gear meshing, and this machining
method is termed as two-parameter generating machining [2] according to two kinds motions, i.e. meshing between the
cutter and gear blank, and the cutter feeding relative the gear. Actually, this machining method is also effective to general
profiles like arc gear, cycloid gear, sprocket etc. Accurate geometric simulation for the machining process of two-parameter
generating is vital to evaluate the machining precision, investigate the potential interferences and overcutting, estimate the
working condition of cutting edge, and it is helpful to improve the machining process and optimize the cutter structure in

∗
Corresponding author at: Key Laboratory of Education Ministry for Modern Design & Rotor-Bearing System, Xi’an Jiaotong University, Xi’an 710049, P.R.
China.
E-mail address: jhong@mail.xjtu.edu.cn (J. Hong).

https://doi.org/10.1016/j.apm.2019.05.021
0307-904X/© 2019 Elsevier Inc. All rights reserved.
38 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

Nomenclature

αn normal pressure angle of involute gear (°)

βc helix angle on pitch circle of cutter (°)
βg helix angle on pitch circle of gear (°)
Г cross angle between gear axis and cutter axis
ϕs rotation angle of gear for engaging gear
ϕe rotation angle of gear for exiting
ωac additional angular speed of cutter (arc/s)
ωc angular speed of cutter (arc/s)
ωg angular speed of gear (arc/s)
Ce cutting edge curve
dac direction of additional rotation for cutter
dc rotation direction of cutter
dg rotation direction of gear
E0 eccentricity of cutter along zc -axis (mm)
Eg minimum distance between gear axis and cutter axis (mm)
fc feed speed along zg -axis (mm/s)
fg shaft section of gear blank
Ge points on gear slot surface
kc rotation direction of cutter (+1 denotes right hand, and −1 denotes left hand)
kg rotation direction of gear (+1 denotes right hand, and −1 denotes left hand)
km type of gear blank (+1 for external, and −1 for internal)
mn normal module of involute gear (mm)
Ne cutting edge number of one tooth
Ng point number for machined profile distinguishing
Np point number of cutting edge
Nt number of partition for the generating time interval
Rc pitch radius of cutter (mm)
Re instant contact point on gear rack
Rg pitch radius of gear (mm)
SVC swept volume of cutting edges
Te instant contact point on gear slot surface
zc teeth number for cutter
zg teeth number for gear blank

further. Plenty of works have been studied for two-parameter generating machining process simulation by four methods, i.e.
analysis, graphic, Boolean, and finite element (FE) method, for different targets.
As the basis of two-parameter generating machining, enveloping equations are formulated analytically via the relative ve-
locity vectors and the correspond normal vectors of the points on the desired surface, which are established according to the
kinematical model of gear machining, like gear skiving [3–7], and generating grinding [8,9]. Commonly, these mathematic
models consist of the configuration of machining, the relationship of motions, and the deduced analytical envelop equation,
but might involve some variants, like modeling the configuration and feed motion as polynomial of time to implement the
gear crowning [10,11] and to estimate the sensitivity of machined error [12,13]. These works proofed that analytical methods
have excellent performances in precision and instantaneous contact investigation. In fact, the analytical method also capable
to process the screw rotors [14,15]. However, in general profiles machining tasks, the potential conditions i.e. singular points,
interferences, and overcuts, restricted the application of analytical methods.
By visualizing a continuous motion via a serial of discrete entities equations [16,17], numerical methods avoid the estab-
lishing of analytical enveloping equations. This manner increases the robustness to deal with the interferences and overcut-
ting [18], and enhance the generality for universal profile machining [19]. As the key operation, boundary searching methods
has been widely studies like RRS [18], boundary point distinguishing [20], etc. The main targets of these studies are focused
on the machined profile distinguishing, however, the instantaneous generating conditions has been barely discussed. Besides,
despite these work have been implemented for specified manufacture tasks, a general model of two-parameter generating
model, which contains complete geometric and kinematic parameters of general gear machining methods, was still in lack.
Boolean methods also have robust performance in calculating the machined profile and simulating the complete gener-
ating machining process. In the early time, the Boolean methods were implemented with combing the numerical ideology,
such as the element removal [21], and openGL assisted discrete enveloping [22], to identify the machined profile. Nowadays,
the Boolean methods mainly focus on the detail geometries of the complete generating process [23–26] like the material
removal, chip thickness evaluation, etc. Actually, the core computation is performed via the software SDK, while the basic
 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 39

Fig. 1. Configuration of two-parameter generating machining for cylindrical gears.

mathematical model of two-parameter generating machining has not been studied. Similarly, the FE methods [27,28] inves-
tigated the physic factors of the working condition of the complete process like cutting force, heat conduction, tool wear,
chip curling and so on, the geometries of which were prepared based on the fundamental mathematical model of the two-
parameter generating machining. Although the two lateral methods are focused on the application technology, the study of
the mathematical model for generating machining is necessary as their basis.
As the references have indicated, the studies on general mathematical model for two-parameter generating machining
are still required. With considering the excellent performances like the precision and the instant investigation of analytical
methods, and the robustness and the generality of the numerical methods, in this study, a general mathematical model for
two-parameter generating machining of involute cylindrical gears has been developed with adopting discrete enveloping,
in which the instantaneous contact was investigated in further. Section 2 introduced the basic general mathematical model
by configuration and motions. Section 3 developed an algorithm for machined profile distinguishing and correspond instant
contact analyzing via discrete enveloping. Section 4 carried out 5 numerical simulations to verify and investigate the model.
For the consistence of this study, Cartesian coordinates and homogeneous coordinate transformation are adopted. There,
the superscript of vector indicates its current coordinate system, and the matrix is transforming from the superscript indi-
cated coordinate system to the subscript indicated system.

2. Mathematical modeling for two-parameter generating machining

Two-parameter generating machining for involute gears is a typical application of cross-axis gear meshing. Its mathe-
matical model for multi-type gear generating machining is established in terms of the configuration of machining systems
and the kinematic relationships. Besides, the generation principle is introduced in brief.

2.1. Configuration of generating machining

In general, the involute profile manufacturing is performed by generating motion according to the principle of cross-axis
gear meshing. As shown in Fig. 1, cutter coordinate system Oc -xc yc zc is fixed on the cutter, and rotates along the cutter axis
with angular speed ωc relative to the coordinate system O2 -x2 y2 z2 which is fixed on the ground; gear coordinate system
Og -xg yg zg is fixed on the gear blank, and rotates along the gear axis with angular speed ωg , relative to the coordinate system
O1 -x1 y1 z1 which is fixed on the ground. In initial, the xc -axis and xg -axis are coincided, and the minimum distance between
the zc -axis and zg -axis is defined as center distance Eg . It is determined by the radiuses Rc and Rg respectively for the pitch
circles for the cutter and the gear blank as follow:
Eg = Rg + km Rc (1)
where km denotes the type of gear, in which km =1 means external gear blank, and km =–1 means internal gear blank.
The precondition of cross-axis gear meshing [1] indicates that the cutting teeth and gear blank must take the same
normal modules mn , and the normal pressure angles α n , respectively. With respect the cutting teeth number zc and the
teeth number zg of gear blank, the pitch radius Rc for the cutter and Rg for the gear blank is given as follow:
Rc = 0.5zc mn cos−1 (βc ) (2)

Rg = 0.5zg mn cos−1 (βg ) (3)

40 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

Table 1
Coefficients of rotation directions.

dc dg dac

 >0 −km km km kg
 <0 km −km km kg

Fig. 2. Principle of two-parameter generating machining.

Normally, except the gear shaping adopts parallel axis, non-zero cross angle between the cutter axis and gear blank axis
is the key to perform the material removal for gear hobbing, gear shaving, and gear skiving. The non-zero setup angle Г is
termed as shaft angle, and is defined by the helix angle β c of the cutter pitch circle and helix angle β w of gear blank pitch
circle with respect the gear type as below:
 = kc βc + km kg βg (4)
where, kc denotes the rotate direction of cutter, kc =1 means right hand rotation, and kc =−1 means left hand rotation; kg
denotes the rotate direction of gear blank, kg =1 means right hand rotation, and kg =−1 means left hand rotation.
In practical application, the positioning of cutter might be adjusted along its axial direction in order to improve the
working condition of cutting edges. This axial offset from Oc to the rake flank along zc -axis is termed as eccentricity E0 .

2.2. Relationship of generating motions

During the generating machining process for involute gears, the cutter and the gear blank perform a meshing motion
with constant transmission ratio, and a synchronous axial feed motion is implemented along the gear axis to cut off the
complete gear slot. According to the gear meshing principle, it is known that the cutter rotation with speed ωc and the gear
blank rotation with speed ωg constitute the main cutting motion to generate the desire slot profile, and a rotation ωca is
added to the cutter to ensure the meshing condition when axial feed motion fc is performed. The relationships among this
motions are given as follows:
ωc zg
= (5)
ωg zc
fc sin(βg )
ωca = (6)
Rc cos(βc )
For machining methods adopting non-zero shaft angle, proper rotation directions of cutter and gear blank are significant
to ensure the cutting edges engage the gear blank along feed direction. All the direction coefficients, dc for the rotation of
cutter ωc , dac for the cutter additional rotation ωca , and dg for the rotation of gear blank ωg are specified as in Table 1.
There, +1 indicates rotation along anti-clockwise direction, and −1 denotes rotation along clockwise direction.

2.3. Principle of two-parameter generating machining

As provided in Fig. 2, a mediate gear rack is involved to investigate the principle of two-parameter generating machin-
ing for involute gears. It is well known that, during the meshing process, the gear slot surfaces (involute helicoids) are
conjugated with the gear rack, and perform a straight instant contact line segment, meanwhile, the gear rack surface is con-
jugated with the helicoid surface that the cutting edges are mounted. These conjugations describe the process of generating
machining as follows: at any moment, one of the cutting edge Ce is conjugated with the gear rack at one point, and the
corresponded point on the gear rack contacts the gear slot surface synchronously; undergoing one engagement, the cutting
edge develops a conjugate curve Re on the gear rack by these contact point, and an corresponded instant contact line Te on
 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 41

Fig. 3. Calculate steps for generating machining: (a) cutting edge definition, (b) swept volume establishing, (c) cutting curves on shaft section calculating,
and (d) machined profile distinguishing.

the gear slot surface is produced; in further, this contact curve Te sweeps the complete gear slot surface through axial feed
motion.
In summary, we can know that the rotation parameter (first) maintains this meshing motion for the generating of gear
slot surface by conjugation principle, while the axial feed parameter (second) employs this conjugation to produce complete
gear slot surface. In addition, the form cutting on the gear slot surface is performed in one point at any instant, and one
contact curve is produced on the gear slot surface during one primary meshing.

3. Generation machining process based on discrete surface enveloping

In terms of the presented conjugate theory of two-parameter generating machining, the gear slot surface can be de-
termined by the cutting edge curves and proper relative motions. Unlike to the traditional analytical methods, discrete
enveloping is adopted in numerical way to enhance the robustness of machining process calculation, such as to deal with
the singularity and double-cut conditions, and to ensure the generality for multi-type of machining tasks. In further, the
forming cutting points among the generating process are discussed consistent with the discrete calculating formulation, and
the correspond simulations about these generation processes were also introduced.

3.1. Profile distinguishing for generating machining process

The profile calculation of two-parameter generating machining for involute gear is described in four steps as follows:
Step 1 is parameters preparation.

(i) To ensure the generality for diverse machining method, as shown in Fig. 3(a), in cutter coordinate system Oc -
xc yc zc , the ith cutting edge is divided into Np points, and the jth point of the ith cutting edge is expressed as
Ce,i (u)=[xi (uj ),yi (uj ),zi (uj ),1]T , where Ne is the cutting edge number of one cutting tooth.
(ii) The shaft section of the gear blank, which is used for enveloping profile distinguishing, is defined as fg : z–zg =0, where
zg is the coordinate of z-axis component and is specified as zero in general.
42 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

(iii) The rotation interval of the cutting tooth that engaging the gear blank, [ts , te ], is determined by identifying the cutting
edges engaging and exiting the addendum circle of gear blank according to the meshing motion. Then, this interval is
split into Nt time moments evenly to approximate the swept volume of cutting edges.
(iv) The machined profile distinguishing for the slot surface of gear blank is performed in Ng discrete segments along the
radial direction on the gear shaft section fg .

Step 2 is swept volume establishing for the cutting edges.

In order to investigate the actions of cutting edge relative to the gear blank, as shown in Fig. 3(b), the cutting edges Ce c
are transformed from cutter coordinate system to the gear coordinate system at every t moment as follow:
Cge (u, t ) = Mcg (t ) · Cce (u ) (7)
c
where Mg is the transform matrix from cutter coordinate system to the gear coordinate system. It is ascertained according
to the mathematical model for two-parameter generating machining as below:
Mg c = Mg 1 · M1 2 · M2 c (8)
Here, all the elements are specified as follows:
⎡ ⎤
cos(dc ωc t + dac ωac t ) − sin(dc ωc t + dac ωac t ) 0 0
⎢ sin(dc ωc t + dac ωac t ) cos(dc ωc t + dac ωac t ) 0 0 ⎥
M2 (t ) = ⎣
c
− fc t ⎦
(9)
0 0 1
0 0 0 1
⎡ ⎤
1 0 0 Eg
⎢0 cos() sin() 0⎥
M1 2 =⎣
0⎦
(10)
0 − sin() cos()
0 0 0 1
⎡ ⎤
cos(dg ωgt ) sin(dg ωgt ) 0 0
⎢− sin(dg ωgt ) cos(dg ωgt ) 0 0⎥
Mg (t ) = ⎣
1
0⎦
(11)
0 0 1
0 0 0 1
Hereafter, the swept volume of all the cutting edge (SVC) for one cutting tooth, which is families of cutting edge curves
among the effective rotation interval [ts , te ], is approximated by the discrete cutting edge curves as illustrated in Fig. 3(b).
Consequently, the expression of SVC is formulated numerically as follows:
Np

Nt 
Nt 
Ne 
SVC = Cge (u, tk ) = Mcg (tk ) · Ce,i (u j ) (12)
k=1 k=1 i=1 j=1

where, time moment tk is given as:

(Nt − k ) (k − 1 )
tk = ts + te (13)
Nt − 1 Nt − 1
Step 3 is calculation of the cutting curves on gear shaft section.
The machining principle of two-parameter generating machining has indicated that the SVC is the result of the meshing
motion, and it is contributed to the instant contact line, while the feeding motion is in charge of the complete slot surface
machining. Therefore, as shown in Fig. 3(c), the SVC produces the profile of gear slot on the gear shaft section fg with
following the feed motion Ms that defined by the gear geometrical structure as below:
⎡ ⎤
cos(kgt ) − sin(kgt ) 0 2Rg tan−1 (βg )t
⎢ sin(kgt ) cos(kgt ) 0 0 ⎥
Ms (t ) = ⎣ ⎦ (14)
0 0 1 0
0 0 0 1
Accordingly, intersection points between the SVC and the gear shaft section fg satisfy followed equation f1 :
f1 : Ms (τ ) · SVC − fg = 0 (15)
where, τ is the parameter of feed motion for each intersect point.
With considering the discrete formulation of SVC, each of the cutting edge points is contributed to the profile cutting
on fg . For instance, the intersect point Ei (uj , tk ) on fg that corresponding to the discrete point Ce,i g (uj , tk ), which is the
jth cutting edge point on the ith cutting edge at kth moment, can be ascertained by substituting Ce,i g (uj , tk ) into Eq. (15),
and then figuring out the proper τ 0 with carrying out numerical iterative search algorithms like Newton–Raphson method.
Finally, the intersection point is fixed as Ei (uj , tk )=Ms (τ 0 )·Ce,i g (uj , tk ). In this way, a serial of discrete intersect curves of the
SVC can be identified.
 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 43

Fig. 4. Instant contact point extraction.

Step 4 is machined profile distinguishing.

As shown in Fig. 3(d), to increase the robustness of machined profile distinguishing, as the machined profile of gear slot,
the external enveloping profile of all these intersect curves on gear shaft section, is distinguished as a serial of discrete
points in the radial direction of gear blank. The procedure is described as follows:

(i) The radial range of the machined profile [Rmin ,Rmax ] is ascertained as to the farthest point M on the x1 -axis that
intersect with the cutting edges of SVC and the addendum circle of the gear blank, respectively.
(ii) Dividing the range [Rmin ,Rmax ] evenly into Ng interval along the symmetric line L that coincides with x1 -axis, and
specifying each interval an unique x-coordinate value (xn ).
(iii) For each xn , the intersection points between the plane: x=xn and all the intersection curves are calculated. Then the
point Gmin that takes minimum y-component and the one Gmax takes maximum y-component are specified as the
external enveloping profile points of two sides, respectively. It is worthwhile that the corresponded time moment kn ,
and the cutting edge sequence number in of these two profile points are recorded for lateral instant cutting condition
analysis.
(iv) After specify all the profile points within range [Rmin ,Rmax ], the complete machined profile of gear blank on fg is
generated by connecting the profile points following the radial sequence in each side.

3.2. Extraction for instant cutting contact points

The working principle of two-parameter generating machining has pointed out that each cutting edge performs a point
contact on the desired involute helicoid of gear blank at every instant. We can deduce that, as Fig. 4 provided, each profile
point Gn must be generated by a cutting edge point Tn at an instant moment tn . As the machined profile distinguishing
has indicated, the instant moment tn and the executed cutting edge number in of each profile point Gmin (Gmax ) have been
determined and recorded. Thus, with combining the in th cutting edge at tn moment, and the feed motion Ms , we can
establish equation f2 for the point Tn g , and it can be solved as a function of variable τ by carry out numerical iteration

Fig. 5. The simulation for two-parameter generating machining process: (a) the instantaneous meshing and trajectory of instant contact line, and (b) the
engaged cutting edge segments.
44 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

Table 2
Basic parameters for two-parameter generation machining simulations.

Items, symbol [unit] Gear shaping Gear skiving Gear hobbing Gear shaving General skiving

Gear blank parameters

Normal module, mn [mm] 3 2 3 2 –
Normal pressure angle, α k [°] 20 30 20 20 –
Number of teeth, Zg 54 20 20 30 80
Helix angle, β g [°] 20 15 12 10 10
Hand of rotation Right hand Right hand Right hand None Right hand
Cutter parameters
Number of teeth, Zc 36 12 1 40 20
Helix angle, β c [°] 20 5 80 0 20
Hand of rotation Left hand Right hand Right hand None Right hand
Configuration parameters
Center distance, Eg [mm] 143.664 8.6597 39.3084 70.4628 75
Setup angle, Г [°] 0 20 −92 −10 10
Eccentricity, E0 [mm] 0 0 0 0 0
Task type, km 1 −1 1 1 −1
Kinematic parameters
Rotation of gear blank, [arc/s] 0.01π 10π 5π 10π π
Rotation of cutter, [arc/s] 0.015π 16.667π 20π 13.333π 4π
Additional rotation of cutter, [arc/s] 0.0633 −4.7929e−4 0.0139 4.3412e−4 −7.3917e−4
Axial feed of cutter, [mm/s] 10 0.1 0.1 0.1 0.1
Calculation parameters
Number of cutting edge, Ne 1 1 12 3 1
Number of edge point, Np 60 60 60 60 50
Number of solid for swept, Nt 91 91 181 181 91
Period of machining, [ts ,te ] [s] [−8.40 0,8.40 0] [−0.0 027,0.0 027] [−0.0 04,0.0 04] [−0.0 018,0.0 018] [−0.014,0.014]
Number of machined profile, Ng 200 200 200 200 200

search algorithms.
f2 = Ms (τ ) · Gn − Cge,in (u, tn ) = 0 (16)
The instant contact point Tn at tn moment is given by, τ 0 , the solution of f2 as follow:
g

Tgn = Ms (τ0 ) · Gn (17)

All these instant contact points that correspond to the complete machined profile demonstrate an instant contact line
lied on the gear slot. It is the forming trajectory during the meshing between a pair of cutting tooth and gear slot. It is
significant to analyze the working condition of cutting edges during the generating machining. For example, the SVC and
the undercutting gear blank can be modeled by commercial application software, and then the FE simulations [27,28] can
be evoked in further to evaluate the working condition of cutting edges. Similarly, the element cutting tool methodology
[29] also can be involved for some analytical investigations, like indicating the instantaneous geometry of cutting, and esti-
mating the force-heat status of the generating machining process. All these studies are contributed to the optimum design
of the cutter and the machining process.
In practical, this instant contact point extraction methodology is effective to general profile machining, like cycloid, el-
lipse, etc. However, compare with the analytical enveloping equations, there are still some limitations on the performance
of the instant contact point extraction. Firstly, the precision of the instant contact points is affected, not only by the number
of Ng and Nt since the enveloping profile points are distinguished approximately, but also result to that not the standard
involute curve points but the intersection points are adopted as the candidates for enveloping points. Secondly, the current
instant contact point extraction lacks the capability to deal with time-vary feed motion.

3.3. Simulation of two-parameter generating machining process

The instantaneous meshing status, the spatial conjugate trajectory, and the engagement of cutting edge segments are
the mainly concerns of the simulation of the two-parameter generating machining process. As shown in Fig. 5, these basic
mathematic models are analyzed as follows:
(i) For each instant contact points Tn , with the help of its correspond known moment tn , the instantaneous meshing
status between the cutting edges and the gear blank can be illustrated intuitively in the ground coordinate system
O1 . The cutting edge points Ce and the gear slot surface Gg are given by transforming to the coordinate system O1 as
Ce 1 and Gg 1 respectively as follows:
C1e = M21 · Mc2 (tn ) · Ce (18)

G1g = Mg1 (tn ) · Gg (19)

 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 45

Fig. 6. Simulation for helical gear shaping: (a) configuration of helical gear shaping, (b) deviation of calculate profile, (c) profile enveloping on the gear
shaft section, and (d) instant contact lines of gear shaping.

where M1 g is the inverse matrix of Mg 1 .

(ii) During the generating machining process, the spatial trajectory of the instant points can be demonstrated in the
coordinate system O1 via transforming each point Tn g from gear coordinate system to the coordinate system O1 as
follows:

T1n = Mg1 (tn ) · Tgn (20)

(iii) For machining methods that each tooth contains multiple cutting edges, the detailed engagement of cutting edges
need to be figured out as serials of discrete points Tn c (Ce,n c ) by transforming each of the instant contact point Tn g to
the cutter coordinate system as follows:

Tcn = Mgc (tn ) · Tgn (21)

g
where Mc is the inverse matrix of Mg c.

4. Cases study

In order to verify the generality and the effectiveness of the proposed model, four kinds of typical generating man-
ufacturing methods for helical involute gear i.e. gear shaping, gear hobbing, gear shaving, and gear skiving as well as a
non-involute gear skiving are simulated, then the deviations between the machined profiles and the standard involute
46 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

Fig. 7. Simulation for internal helical gear skiving: (a) configuration of gear skiving, (b) spatial enveloping of gear skiving, (c) cutting edge and its envelop-
ing profile, and (d) deviation of calculated profile.

curves are investigated. The parameters of the cutters, gear blanks, and the corresponded machining configurations as well
as the calculation related parameters are shown in Table 2.

4.1. Gear shaping

A helical gear shaping with parallel-axis is simulated at first to improve the basic performance of proposed mathematical
model as shown in Fig. 6(a). During the helical gear shaping process, the meshing motion is divide into a serial of rotation
angles, and in each of them the gear is fix while the cutter only performs the helical feed motion according to the geometry
of gear blank. The entire meshing motion produces the complete profile of gear slot on the shaft section as Fig. 6(c). The
deviations of the simulated profile from the theoretical involute curve are illustrated as in Fig. 6(b), the maximum one that
no larger than 0.12um proofs the effectiveness of this method. In further, the instant contact lines (P1 -P2 -P3 ) and (Q1 -Q2 -Q3 )
that are extracted by the profile points on fg , as drawn in Fig. 6(d), are consistent with the parallel-axis gear meshing.

4.2. Internal gear skiving

The power skiving cutter and the gear blank are configured as shown in Fig. 7(a), while the SVC is established according
to kinematic parameters as drawn in Fig. 7(b), concurrently, the machined profile is distinguished as shown in Fig. 7(c). In
the basis of the distinguished profile points and the correspond action time moments, the instant contact points (Q3 -Q4-P0
and Q1 -Q2 -P0 ) that lied on the gear slot surface and their spatial trajectories (P3 -P4-P0 and P1 -P2 -P0 ) in O1 -x1 y1 z1 coordinate
system are calculated. As illustrated in Fig. 7(b), the tip of right cutting edge engages the gear slot surface at point Q4 at
first, then the right cutting edge generates the slot surface gradually along the instant contact line Q4 -Q3 , and exits the gear
slot surface at point Q3 , in the meantime the tip of right cutting edge cuts out the root of slot along the instant contact
line Q4 -P0 ; Independently, the left cutting edge performs gear slot surface generating along instant contact line Q1 -Q2 from
Q1 to Q2 , and also performs the gear root cutting along instant contact line P0 -Q2 from P2 to Q2 . The corresponded spatial
trajectories demonstrate the same generating conditions for the cutting edges in two sides. These generating processes are
reasonable compare with the cross-axis gear meshing. In addition, the segments of instant contact lines that corresponding
 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 47

Fig. 8. Simulation of helical gear hobbing: (a) configuration of helical gear hobbing, (b) deviation of machined profile, (c) instant contacts of left cutting
edges, and (d) instant contacts of right cutting edges.

to the involute helicoid are working as straight lines, which are consistent with the cross-axis gear meshing. It also validates
the correctness of the contact curve extraction.
Besides, comparing with the standard involute curve, as shown in Fig. 7(d), the maximum deviation of the simulated
profile is less than 0.09um. It proofs this method is practicable.

4.3. External helical gear hobbing

The helical gear hobbing is installed as shown in Fig. 8(a), in which 24 cutting edges on the same cutting tooth are em-
ployed to perform the gear slot machining. By transforming all the cutting edges into the gear coordinate system according
to the specified discrete time interval, the intersect curves on the shaft section of gear blank and their external enveloping
profile are distinguished by propose method as shown in Fig. 8(b). Compare with the standard involute curve, the maximum
deviations, i.e. 1.6 μm, 0.4 μm, and 0.18 μm, are decreased along with the increase of the cutting edge number 12, 24, and
36, respectively. It is consistent with the analysis in [30], since the theoretical involute curves can only be manufactured
by a continuous generation between the basic worm and gear like generating grinding, however, this continuous machining
process is substituted by several cutting edges in gear hobbing. As a result, the enveloping surfaces for all the cutting edge
contribute to a discontinue enveloping on fg as an approximate polygon, and it produces this theoretical profile error during
gear hobbing.
The generating machining processes for the left and right sides are demonstrated as shown in Fig. 8(c) and (d), respec-
tively. In the left side, the generating cutting is started at P1 by cutting edge tip K1 , and is developed along the spatial
instant contact line P1 –Pn , and is finished at Pn by the root of cutting edge Kn ; the right side performs similarly condition,
in which the generating is started at P1 by the root of cutting edge K1 , and is implemented along the straight spatial instant
contact line P1 –Pn , and is exited at Pn by the cutting edge tip Kn . These statuses are consistent with the meshing of a pair of
48 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

Fig. 9. Simulation of helical gear shaving: (a) configuration of helical gear shaving, (b) deviation for machined profile, (c) front view of instant contact of
left cutting edge for task 1, (d) instant contact of left cutting edge for task 1, and (e) instant contact of right cutting edge for task 1, (f) front view of instant
contact of left cutting edge for task 2, (g) instant contact of left cutting edge for task 2, and (h) instant contact of right cutting edge for task 2.

cross-axis gear. Besides, the spatial trajectories of the instant contact line indicate that, at each cutting edge, only a segment
cutting edge curve takes apart in the generating of the gear slot surface as the practical working condition. These results
show the effectiveness of proposed method to figure out the instant contact points and the engage cutting edge segment
when multiple cutting edges have been involved.

4.4. External helical gear shaving

Two gear shaving tasks are performed by a spur cutter that contains three cutting edges in each tooth as shown in
Fig. 9(a). For task 1 and task 2, the intervals of adjacent cutting edges along zc -axis are 2 mm and 0.3 mm, respectively.
 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51 49

Fig. 10. Simulation of general profile skiving: (a) designed cutting edge curve, (b) machined profile by skiving, (c) top view of skiving process, (d) instant
contact for left side, (e) instant contact for right side, and (f) front view of skiving process.

The enveloping profile on the gear blank shaft section of task 1 is simulated as shown in Fig. 9(b), in which the maximum
deviation that less than 0.25 μm verifies the robustness of this method.
The generating process for gear shaving task 1 is indicated as shown in Fig. 9(d) for the left side and as Fig. 9(e) for the
right side, respectively. The left gear slot is engaged at Q3 by edge #1 at first, and then the root aera of the gear slot is
produced by all the three cutting edges following a disorder Q3 -Q2 -Q1 ; meanwhile, after finishing a tiny transitional curve
segment that adjacent to the involute around Q3 (Q4 ) by edge #1, mainly generating of the involute profile is performed
by edge #2 along the instant contact line Q4 -Q5 , of which the spatial trajectory P4 -P5 is a straight line. Similarly, the right
side cutting performs an inverse order relative to the left side, in which the mainly involute is generated by edge #2 along
the instant contact line Q1 -Q2 at first, and the instant contact point develops a straight trajectory P1 -P2 ; concurrently, the
transitional curve of the gear slot is machined at Q5 by edge #1 at first, then is produced with mixed disorders (Q5 -Q4 -Q3
and Q2 Q3 ) gradually, and is finished when edge #3 departing Q3 . It deserves notice that, the involute segment generating is
performed all by edge #2 due to the range of spatial instant line P4 -P5 is located inside the interval between edge #1 and
edge #3 along zg -axis as Fig. 9(c) drawn. The task 2 shows unlike as in Fig. 9(g), accordingly, all the three cutting edges take
part in the involute segment generating for both side as shown in Fig. 9(g) and (h), respectively. These investigations proof
the proposed method is capable to simulate the detailed generating machining process for tooth taken multiple cutting
edges.

4.5. Internal power skiving for general profile

To proof the generality of this mathematic model, an internal skiving task is performed for a general profile as follows:
at first, as shown in Fig. 10(a), the cutting edge curve is designed by Jia et al. [31] for a part with transversal profile as
under.
f3 : x = 100 + cos(y ) y ∈ [−π , π ] (22)
However, the designed cutting edge curve cannot produce the desired profile reversely on the count of double-cut are
occurred during the enveloping process. It can be clearly observed via the distinguished machined profile as drawn in
Fig. 10(b). At last, the instant contact conditions of the generating process are investigated for the two sides as shown
in Figs. 10(c)–(f). We can obtain some conclusions, i.e., unlike the straight lines for involute helicoids, the trajectories of the
50 K. Jia, J. Guo and S. Zheng et al. / Applied Mathematical Modelling 75 (2019) 37–51

instant contact points are spatial curves; compare to the cutting edge plane as shown in Fig. 10(f), the instant contact lines
might perform multiple intersect points, which indicates all these points are generated in the same time. This simulation
proofs the generality of proposed method.

5. Conclusions

Based on the enveloping theory, this study proposed a general mathematical model to identify the machined profile and
to analyze the instant contact for two-parameter generating machining, especially for the involute gears. The correctness of
this model has been verified and investigated by 5 numerical simulations. The main conclusions are summarized as follows:

(i) The proposed model has a robust character to obtain the machined profile for two-parameter generating machining,
not only for involute gear but also general profiles. With adopting a serial of cutting edge curves relative the gear
blank to instead of the continuous motions, the external enveloping profile is distinguished numerically as figure out
the limitation points in radial interval. The maximum deviations between the simulated profiles and correspond stan-
dard involute curves were less than 0.25um for gear shaping, gear skiving, and gear shaving, proof the practicability
and the correctness of this model. Furthermore, the maximum deviation was decreasing along with the cutting edge
number increase in gear hobbing.
(ii) This model performed excellent capability to investigate the instant contact during the two-parameter generating
process and to distinguish the engaged segments on cutting edges when multiple-cutting edge were taken. With
extracting the implied sequence numbers of motion and that of acted cutting edge for each discrete profile points,
the instant contact between cutting edge point and slot surface was figured out reversely by tracing the profile point
on the rake flank along feed motion. In further, brief coordinate transformations were modeled to determine the
engaged cutting edge segments based on instant contact points. The straight trajectories of instant line for involute
gear machining and the one of general profile skiving shows the correctness and the generality of propose model.
(iii) The accuracy of proposed method was influenced by the number of cutting edge point Np and the number of parti-
tion for the generation motion interval Nt . Larger number indicated the enveloping is approximate to the theoretical
condition, and contributed to reduce the deviation. Independently, increasing the profile distinguish number Ng is
only helpful to refine the instant contact lines of the generating process.
(iv) This study has only investigated the standard configuration for gear generating machining, in which the center dis-
tance and the feed motion are constant. In further study, these configuration parameters and motions will be ex-
pressed as polynomial of time to extend the capability of this mathematical model, such as the modification for
crown gears.

Acknowledgments

The authors are grateful to the anonymous referees for their helpful suggests, which greatly helped to improve the quality
of this work, and also would like thanks for the financial support provided by the National Natural Science Foundation
under Grant No. 51705403, the China Postdoctoral Science Foundation under Grant No. 2017M623158, and the Fundamental
Research Funds for the Central Universities under Grant No. xjh2019003.

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